Scenario: Outdoor air quality sensor needs to run 24/7 for 10 years. Device consumes 15 mW continuous (sensor + LoRa transmissions every 15 min). Location: Seattle (known for cloudy weather). Design a complete energy harvesting system with sizing calculations.
Step 1 - Calculate Daily Energy Requirements:
Power: 15 mW continuous
Daily energy: 15 mW × 24 hours = 360 mWh/day
Step 2 - Determine Solar Panel Size for Seattle Climate:
Seattle solar conditions:
- Best case (summer): 6 hours full sun, 100 mW/cm² → 600 mWh/cm²/day
- Typical (spring/fall): 4 hours partial sun, 60 mW/cm² → 240 mWh/cm²/day
- Worst case (winter): 2 hours dim sun, 30 mW/cm² → 60 mWh/cm²/day
Panel efficiency: 20% (typical monocrystalline)
Energy per cm² per day:
- Best: 600 × 0.20 = 120 mWh/cm²/day
- Typical: 240 × 0.20 = 48 mWh/cm²/day
- Worst: 60 × 0.20 = 12 mWh/cm²/day
Required panel area (design for worst case + 50% margin):
Worst case requirement: 360 mWh/day
Panel harvest: 12 mWh/cm²/day
Required area: 360 / 12 = 30 cm²
With 50% margin: 30 × 1.5 = 45 cm²
Panel dimensions: 7cm × 7cm (49 cm², commercially available size)
Step 3 - Calculate Battery Capacity for Consecutive Cloudy Days:
Assume 7 consecutive days of worst-case weather (Seattle winter):
Daily deficit when solar = 0: 360 mWh
7-day buffer: 360 × 7 = 2,520 mWh required
Convert to mAh at 3.7V Li-ion:
Capacity = 2,520 mWh / 3.7V = 681 mAh
Round up to standard size: 1000 mAh (provides 14-day buffer)
Step 4 - Verify Long-Term Energy Balance:
Annual energy budget (Seattle: 150 sunny days, 120 partial, 95 worst):
Sunny days: 150 × (49 cm² × 120 mWh/cm²) = 882,000 mWh
Partial days: 120 × (49 × 48) = 282,240 mWh
Worst days: 95 × (49 × 12) = 55,860 mWh
Total harvest: 1,220,100 mWh/year
Annual consumption: 360 mWh/day × 365 = 131,400 mWh/year
Surplus: 1,220,100 - 131,400 = 1,088,700 mWh (8.3x requirement)
Result: System has 8.3x annual energy surplus, easily handles worst-case winter and unexpected cloudy periods.
Step 5 - Select Components:
Solar panel:
- Size: 7cm × 7cm (49 cm²)
- Voltage: 5V nominal (4.5-6V range)
- Current: 200 mA peak
- Cost: $8-12
Battery:
- Type: 3.7V Li-ion 18650
- Capacity: 1000 mAh (14-day worst-case buffer)
- Cost: $3-5
Charge controller:
- IC: TP4056 or similar
- Features: MPPT solar charging, Li-ion charging curves, over-discharge protection
- Cost: $1-2
Voltage regulator:
- 3.3V buck converter (if device runs on 3.3V)
- Efficiency: 85-90%
- Cost: $0.50-1
Total BOM cost: $12.50-20 (vs $5-10 for non-rechargeable batteries replaced yearly = $50-100 over 10 years)
Step 6 - Implementation Diagram:
[Solar Panel 5V] → [TP4056 Charge Controller] → [1000mAh Li-ion Battery]
|
v
[3.3V Buck Regulator]
|
v
[Air Quality Sensor + LoRa]
Step 7 - Field Installation Guidelines:
- Orientation: Face south (northern hemisphere) at 45° tilt for optimal winter sun
- Shading: Ensure no trees/buildings block sun from 9am-3pm
- Cleaning: Clean panel quarterly (dust reduces efficiency by 15-25%)
- Monitoring: Device reports battery voltage; <3.2V indicates charging issue
Step 8 - Failure Mode Analysis:
| 14+ consecutive cloudy days |
<1% in Seattle |
1000 mAh gives 14-day buffer |
System survives |
| Panel degradation (20-year) |
100% (0.5%/year) |
8.3x surplus absorbs 90% degradation |
Still viable at year 20 |
| Battery aging (3-year cycle) |
100% |
Battery replacement every 3 years |
Design includes easy access |
| Heavy snow covering panel |
5% of winter days |
Auto-wake on low battery, clear snow |
1-day outage acceptable |
Comparison to Battery-Only:
Non-rechargeable batteries (2x AA lithium, 3000 mAh): - Lifetime: 3000 mAh × 3V / 15 mW = 600 hours = 25 days - 10-year cost: (365 / 25) × 10 years × $6/set = $876 - Labor cost: 146 battery replacements × $50/visit = $7,300 - Total 10-year cost: $8,176
Solar + rechargeable:
- Initial: $20 (solar + battery + controller)
- Battery replacement: 3 times in 10 years × $5 = $15
- Total 10-year cost: $35
ROI: 234x return on investment vs battery-only approach
Why This Design Works:
- Panel sized for worst case: Seattle winter is among the worst in the US; system works anywhere
- Large battery buffer: 14-day capacity handles extended cloudy periods without shutting down
- 8.3x annual surplus: Compensates for panel degradation over 20+ year lifespan
- Low cost: $20 upfront eliminates $8,000+ in battery and labor costs
- Maintenance-free: Battery replacement every 3 years vs battery swap every 25 days